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9 Service Manual

(/qs3/pubsys2/xml/en/manual/3666087/3666087-titlepage.html)

Failure Analysis Inspection

Inspect the piston rings for the following:
Abrasive wear.
Note : Abrasive wear of the intermediate ring can be
indicated by a rapid reduction of the dark finish coating
on the front face of the ring, in some cases, to the point
where the dark finish coating is no longer visible (A).
This is commonly referred to as full face ring wear. This
rapid reduction will typically leave a sharp edge on the
bottom of the intermediate ring. Abrasive wear can also
be indicated by concentrated vertical scratches on the
top ring (B).
Abrasive wear can be caused by:
1. Ingested abrasive material
2. Inadequate cleaning during a previous repair
3. Particles embedded in the bore
4. High soot content in the lubricating oil from extended oil
drain intervals
5. Scuffing and scoring.

Note : Scuffing and scoring is indicated by heavy

scratches, metal discoloration, and voids (B).
Scuffing and scoring can be caused by:
1. Engine overheating
2. Oil dilution
3. Improper maintenance of the lubrication system
4. Piston cooling nozzle malfunction
5. Oil ring plugged by deposits.
Note : Scuffing and scoring on the piston rings indicates
a breakdown of the oil film on the cylinder bore wall,

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causing transfer of material from the piston ring face to

the cylinder bore.

Note : Oil ring plugging is indicated by deposits on the

oil ring grooves (B).
Oil ring plugging can be caused by:
1. Low engine operating temperatures - long periods of idling
or a cooling system malfunction
2. Extended oil change intervals
3. Use of the wrong grade of engine oil
4. Use of a poor quality engine oil.
Note : Plugging of the oil ring drains restricts oil drain
back, which floods the piston ring belt area, resulting in
a loss of oil control.
Note : The following measurements are intended for
inspecting new piston rings.
Note : Before completing this inspection, make sure the
cylinder bore is within specification. Refer to Procedure
001-026 (/qs3/pubsys2/xml/en/procedures/40/40-001-
026.html) in Section 1.

Measure
Front Gear Train
Measure the piston ring gap by installing the piston rings into
the cylinder bore in which they will be used. Position the rings
below the ring reversal area. Position each ring in the cylinder
89 mm [3.5 in] below the top deck (A), and using a clean piston
to square it with the bore.

The piston ring sets are different. While both sets consist of
three rings, the top ring of the turbocharged/aftercooled set
has a keystone profile that operates in a ni-resist insert cast
into the piston. The naturally aspirated (NA) top ring is square
cut and operates in a groove machined into the aluminum
piston.
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Note : The top ring for a turbocharged engine is not the

same as the top ring for a naturally aspirated engine.

Use a feeler gauge to measure the gap.

B3.9, B4.5, and B5.9 Ring Gap

mm in
Oil Control 0.25 MIN 0.010
0.55 MAX 0.022

Piston Ring Gap Cross Referencing Tables

To establish the correct top and intermediate piston ring gap, the part numbers of the piston
rings must be known. If the engine has been rebuilt previously, then check for records of the
parts used during the previous rebuild. If no records are present for the parts used during
rebuild, then this table can’t be used to determine the correct ring gap. If this is the case,
then new piston rings should be used during the rebuild of the engine.
The cross referencing tables are ordered by ring size (Standard, 0.5 mm oversize, then 1.0
mm oversize) and then by part number in descending order. First identify the correct bore /
piston ring size, then find the part number of the rings in the appropriate table.
Note : Piston ring gap sizes are given in mm [inch].
Standard Size Piston Ring
Top ring Intermediate Ring
Part Minimum Maximum Part Minimum Maximum
Number Gap Gap Number Gap Gap
0.22 0.38 0.60 0.86
4897899 4897900
[0.009] [0.015] [0.024] [0.034]
0.26 0.42 0.25 0.61
3959079 3897719
[0.010] [0.017] [0.010] [0.024]
0.26 0.42 0.85 1.21
3947678 3943544
[0.010] [0.017] [0.033] [0.048]
0.35 0.51 0.25 0.61
3937392 3942265
[0.014] [0.020] [0.010] [0.024]

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Standard Size Piston Ring

Top ring Intermediate Ring
Part Minimum Maximum Part Minimum Maximum
Number Gap Gap Number Gap Gap
0.40 0.76 0.25 0.61
3918315 3940777
[0.016] [0.030] [0.010] [0.024]
0.40 0.76 0.55 0.90
3904529 3937393
[0.016] [0.030] [0.022] [0.035]
0.40 0.76 0.25 0.61
3902401 3932519
[0.016] [0.030] [0.010] [0.024]
0.30 0.46 0.25 0.61
2831144 3904531
[0.012] [0.018] [0.010] [0.024]
0.40 0.70 0.25 0.61
3897673 3904530
[0.016] [0.028] [0.010] [0.024]
0.25 0.61
3902400
[0.010] [0.024]
0.25 0.61
3902286
[0.010] [0.024]
0.25 0.55
3897719
[0.010] [0.022]

0.5 mm [0.02 in] Oversize Piston Ring

Top ring Intermediate Ring
Part Minimum Maximum Part Minimum Maximum
Number Gap Gap Number Gap Gap
0.22 0.38 0.60 0.86
4898855 4898858
[0.009] [0.015] [0.024] [0.034]
0.26 0.40 0.85 1.21
3957244 3943545
[0.010] [0.016] [0.033] [0.048]
0.35 0.51 0.25 0.61
3937428 3942266
[0.014] [0.020] [0.010] [0.024]
0.40 0.76 0.55 0.90
3919050 3937430
[0.016] [0.030] [0.022] [0.035]
0.40 0.76 0.25 0.61
3902392 3933583
[0.016] [0.030] [0.010] [0.024]
0.30 0.46 0.25 0.61
2831145 3904347
[0.012] [0.018] [0.010] [0.024]
0.40 0.70 0.25 0.61
3866105 3902393
[0.016] [0.028] [0.010] [0.024]

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0.5 mm [0.02 in] Oversize Piston Ring

Top ring Intermediate Ring
Part Minimum Maximum Part Minimum Maximum
Number Gap Gap Number Gap Gap
0.25 0.55
3866107
[0.010] [0.022]
1.0 mm [0.04 in] Oversize Piston Ring
Top ring Intermediate Ring
Part Minimum Maximum Part Minimum Maximum
Number Gap Gap Number Gap Gap
0.22 0.38 0.60 0.86
4898856 4898859
[0.009] [0.015] [0.024] [0.034]
0.26 0.40 0.85 1.21
3957245 3943546
[0.010] [0.016] [0.033] [0.048]
0.35 0.51 0.25 0.61
3937429 3942267
[0.014] [0.020] [0.010] [0.024]
0.40 0.76 0.55 0.91
3919051 3937431
[0.016] [0.030] [0.022] [0.036]
0.40 0.76 0.25 0.61
3902441 3933585
[0.016] [0.030] [0.010] [0.024]
0.30 0.46 0.25 0.61
2831146 3904348
[0.012] [0.018] [0.010] [0.024]
0.40 0.70 0.25 0.61
3866106 3902442
[0.016] [0.028] [0.010] [0.024]
0.25 0.55
3866108
[0.010] [0.022]
If the piston ring gap is not within specification:
1. Verify the correct type and part number piston ring is being used
2. Verify the cylinder bore is within specification. Refer to Procedure 001-026 in Section 1.
(/qs3/pubsys2/xml/en/procedures/40/40-001-026.html)
3. Verify the piston ring gap measurement is being taken 89 mm [3.5 in] below the cylinder
block deck
4. Try another set of piston rings.

After each ring gap is checked and verified, identify the ring
sets for installation in the cylinder bore where the end gap was
measured.

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Rear Gear Train

Measure the piston ring gap by installing the piston rings into
the cylinder bore in which they will used. Position the rings
below the ring reversal area. Position each ring in the cylinder
89 mm [3.5 in] below the top deck (A), and using a piston to
square it with the bore.

The piston ring type and location can be identified by piston

ring profile.

1. Top piston ring

2. Intermediate piston ring
3. Oil control ring.

Use a feeler gauge to measure the gap.

B4.5 RGT Engines Ring Gap

mm in
Top 0.30 MIN 0.012
0.46 MAX 0.018
Intermediat
0.82 MIN 0.032
e
1.18 MAX 0.047
Oil 0.22 MIN 0.010
0.58 MAX 0.023

If the piston ring gap is not within specification:

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1. Verify the correct type and part number piston ring is being
used
2. Verify the cylinder bore is within specification. Refer to
Procedure 001-026 in Section 1.
(/qs3/pubsys2/xml/en/procedures/40/40-001-026.html)
3. Verify the piston ring gap measurement is being taken 89
mm [3.5 in] below the cylinder block deck
4. Try another set of piston rings.

After each ring gap is checked and verified, identify the ring
sets for installation in the cylinder bore where the end gap was
measured.

Last Modified: 24-Jun-2015

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